Asset Reliability Services

Improve plant productivity through better asset performance and risk reduction

Boost Your Asset and Plant Optimization StrategyGone are the days of extra engineers on staff to troubleshoot and maintain equipment in a reactionary mode to downtime situations. Maintenance staff is being tasked to do more with less, with more advanced control systems on integrated equipment, complicating the in-house maintenance strategy further.

As companies invest in automated control assets to improve their bottom lines, many neglect to invest in the processes and strategies for driving performance out of that equipment. Without strategic processes and documented standard operating procedures for front line maintenance and operations, no manufacturer can expect to truly optimize their production environment – and maximize their profitability.

Rockwell Automation® Asset Reliability Services incorporate a scalable approach to service your asset and reliability demands. We can help you digest the data, develop the solution and perform the remediation. Our domain experts have diverse industry and applications backgrounds, and are certified by the Society for Maintenance and Reliability Professionals. They are well trained on Rockwell Automation products, processes and commonly used applications, as well as products from other manufacturers, enabling them to provide comprehensive support strategies.

Working with Rockwell Automation means more than support of your installed products. You have the benefit of Rockwell Automation servicing that product within your processes and systems, for greater plant productivity and the ability to manage your assets effectively over the remainder of their lifecycle.

Asset Reliability Services can help you accelerate the performance of your operations by empowering people to make smarter, more informed decisions.

Benefits• Enhance maintenance with a

reliability improvement roadmap that provides clear project plans, phased approaches and documented financial returns

• Maximize asset efficiency with our proactive maintenance strategies, while minimizing chronic problem failures

• Manage physical asset changes across sites and enterprise with centralized control equipment health monitoring

• Reduce equipment Mean Time to Restore (MTTR) during unscheduled downtime events by 5-8% with our integrated service

• Streamline operations and maintenance activities throughout the lifecycle of your critical assets, through better use of equipment support processes, resources and parts

• Reduce production, security, safety, compliance and failure risks with our asset reliability programs

Reliability Consulting and Engineering ServicesLarge industrial producers face many challenges when it comes to maintaining equipment on complex production schedules, while driving continuous improvement to their processes. Reliability concepts and techniques can help those who are trying to optimize their production assets, and solve existing problems so that they can stay competitive. Lowering maintenance, repair and operations (MRO) expenses, reducing risk to production and fostering a culture of improvement within the enterprise are just some of the results that can be achieved by implementing reliability practices into your operation.

Reliability Consulting and Engineering Services provide the path to reach these outcomes with the level of program management that works best for you. This portfolio of solutions begins with an assessment to help identify, analyze, diagnose and prioritize improvement areas. Next, the design and implementation of engineering services will help establish improved efficiency and corrective action within your processes. Finally, to sustain improved areas, we offer systems monitoring and program management to streamline the next group of improvement projects within a program framework. Some of the optional services that are performed during these phases include:

Consulting Assessments

Equipment ReliabilityA selected group of equipment is chosen for our reliability consultant to evaluate. We review operational condition vs. designed, maintenance strategies applied, cost of parts and resources, support parts, service response impact, risks of known/ unknown conditions and production criticality.

Maintenance ProgramsA reliability consultant works with you to define the vision and objectives to improve the speed and results along the maintenance journey. To drive value to the organization, we evaluate maintenance strategies that are currently deployed on equipment, service requirements of storeroom, computerized maintenance management system (CMMS) utilization, work order processes and overall MRO costs.

OutcomeOur assessments are built on standards such as ISO 55000 and industry best practices to define your current state, define specific areas of improvement, and provide a roadmap with recommendations and a return on investment for justification.

Engineering Services and Projects

Reliability Improvement ProjectsOur domain experts use knowledge, proven processes and user requirements leveraging appropriate reliability techniques* to drive an outcome with sustainable results.

Resource-based ContractsOur service professionals are available to augment your team’s effectiveness through a dedicated resource contract that applies the right skillset, experience, process training and support tools, helping to ensure sustainable program results.

OutcomeOur reliability engagements can be applied anywhere from a device-level failure mitigation plan to an operational excellence-based maintenance program. These engagements focus on driving improvement of productivity KPIs such as Overall Equipment Effectiveness (OEE), Mean Time to Repair (MTTR) and Mean Time Between Failure (MTBF).

*Common reliability techniques used: criticality analysis, Failure Modes Effect Analysis (FMEA), root cause analysis, Five Whys, spare parts analysis, fault tree analysis, fault code development, training needs analysis, condition based monitoring, maintenance process gap analysis, maintenance strategy development, work order improvements, standard operating procedures/ process mapping, corrective actions plans, MAAR (monitor, analyze, act and review) chart development, CMMS utilization analysis, CMMS Data Cleansing, program management and Reliability-Centered Maintenance (RCM)/ Total Productive Maintenance (TPM) program training.

How We Help YouIt is important to exercise proactive and preventative maintenance strategies to stay a step ahead of costly downtime. Our Reliability Consulting Services professionals can help you determine what equipment is most critical to your operation, create prioritized maintenance plans, and even help optimize an existing computerized maintenance management system to facilitate these activities.

If unplanned downtime does occur, you can be better prepared by knowing the cause and effect of equipment failures within your operational lifecycle. This can reduce troubleshooting time so you can return to production quickly, and help ensure that you have the appropriate stock available for urgent repairs. Our domain experts can augment your MRO team in solving chronic or acute problems that disrupt your production flow, costing you money and unnecessary risk.

Diagnostic Reliability ServiceRockwell Automation Diagnostic Reliability Service streamlines manual engineering and maintenance activities that were previously performed in isolation by providing an automated central asset intelligence system. This system enables proactive notification of risks, tracks device changes and helps streamline maintenance-based decisions.

A proprietary combination of analytics, people, processes and technology, the Diagnostic Reliability Service helps reduce the frequency of unscheduled downtime events and limits the risk of extended production outages. Our system can generate maintenance triggers connected directly to CMMS data to initiate service work and prioritize corrective action plans at lowest cost.

The business impact is lower maintenance, repair and operations (MRO) costs and greater asset utilization, to improve production.

The Diagnostic Reliability Service not only provides asset tracking, but also asset health monitoring combined with engineering services, to offer improved risk mitigation and control system compliance on your critical production assets.

Asset intelligence delivered through this service lets you focus your resources on operational excellence and continuous improvement within your enterprise. By leveraging Diagnostic Reliability Service information and

keeping the asset strategies and risk mitigation plans accurate, you can improve operational efficiency by up to 15 percent. Our Diagnostic Reliability Service is packaged to address common client needs within the framework of a modern Asset Management and Reliability Program.

Common User Scenarios

How can I shrink Mean Time To Restore (MTTR) on critical assets?

How can I help prevent ‘bad actors’ while reducing MRO costs throughout the product lifecycle?

How can I proactively sustain asset health using actionable data to improve manufacturing productivity?

• Locate/ Identify status of troubled devices • Obtain proactive notice of device change/ history • Track device service cycles • Identify device/ system firmware• Determine product safety/ service advisories impact• Mitigate critical equipment risks • Perform a critical/ spare parts gap analysis

• Verify mitigation plans to reduce parts obsolescence

Benefits and Outcomes

• Condition-based, device-level monitoring tool is more powerful than traditional data collection and helps enable system-wide visibility to the health of networked devices

• Helps reduce manual collection time by up to 70 percent with automated device identification and tracking

• Receive alerts of potential risks and issues before they occur with pre-built monitoring and events engine application

• Make operational improvements through better data and analytics

• Troubleshoot remotely and reduce MTTR during downtime events by as much as 5 percent

• Service offering as an operating expense requires less upfront investment and initial results can be seen within 30 days

Features

• Fully automated data collection on all of your networked CIP® devices, whether Allen-Bradley® or from other manufacturers

• Centralized data management• Panel display/interface• Trending and analytics• Alerts and notifications• Configurable events• Reliability engineering experts

“The Rockwell Automation Diagnostic and Reliability Manager is like an EKG heart monitor for process control equipment.”

– Supermajor Oil and Gas Customer

Improve maintenance strategies with automated data collection.

How the System WorksThe Diagnostic Reliability Service helps improve the reliability of your critical equipment control infrastructure, including programmable logic controller (PLC) and programmable automation controller (PAC) processors, I/O and communication modules, system networks and connected power control field assets such as variable frequency drives (VFD), motion axis drives and electronic overloads.

The diagnostic reliability system is connected to the production control network and data center within your firewall, and gathers all networked device information via a common industrial protocol (CIP) message that is designed with automatic device discovery and smart monitoring. It is packaged to include the following capabilities:

• Automated control asset tracking and monitoring• Proactive maintenance analytics and events engine• Alerts and notifications to drive action on intelligence

The system interface delivers pertinent information to users, empowering them with data analysis, reporting and information dashboard screens that share the health of PLC and PAC devices across your device infrastructure. The data is collected using safe and secure methods, and the result is a unified data model that can be centrally viewed and managed.

System engineers – both database and device specialists – configure analytical triggers and device data management rules by type, helping ensure health data context is rich. Our diagnostic reliability engineering service professionals validate, test and deploy the system across your selected facilities or IT environments. The system engineers can also provide user training, periodic maintenance and fine-tuning, as asset criteria and devices change over time.

Rockwell Automation program managers will be versed in your culture, policies and procedures so they can effectively execute the project within your program structure. The program manager’s role is to streamline processes, while handling the unique characteristics of each plant.

For More InformationAsset Reliability Services can help you accelerate the performance of your operations by empowering people to make smarter, more informed decisions. To learn more, contact your local authorized Allen-Bradley distributor or Rockwell Automation sales office, or visit:

www.rockwellautomation.com/global/go/assetreliabilityservices

Publication GMSA–PP019A-EN-P – December 2015 Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Allen-Bradley, FactoryTalk, LISTEN. THINK. SOLVE., Rockwell Automation and Rockwell Software are trademarks of Rockwell Automation, Inc. CIP is a trademark of the ODVA.

The Diagnostic Reliability Service enables system-wide visibility to the health of network devices, and can help reduce manual collection time by up to 70 percent.